Frac pump automatic rate adjustment and critical plunger speed indication

Abstract

A method for regulating a pumping rate of an electrically powered hydraulic fracturing pump includes receiving a step rate limit for one or more pumps, the step rate limit corresponding to at least one of a minimum step rate or a maximum step rate. The method also includes determining a desired pumping rate for the one or more pumps. The method further includes determining a current rate of the one or more pumps. The method includes comparing the desired pumping rate to the current rate. The method also includes determining, based at least in part on the comparison, an adjustment to the current rate. The method further includes determining the adjustment does not exceed the step rate limit. The method includes applying the adjustment to the current rate of the one or more pumps.

1 . A method for regulating a pumping rate of an electrically powered hydraulic fracturing pump, comprising:
 receiving a step rate limit for one or more pumps, the step rate limit corresponding to at least one of a minimum step rate or a maximum step rate;   determining a desired pumping rate for the one or more pumps;   determining a current rate of the one or more pumps;   comparing the desired pumping rate to the current rate;   determining, based at least in part on the comparison, an adjustment to the current rate;   determining the adjustment does not exceed the step rate limit; and   applying the adjustment to the current rate of the one or more pumps.   
     
     
         2 . The method of  claim 1 , further comprising:
 determining a damage accumulation rate for the one or more pumps; and   determining the damage accumulation rate is below a threshold.   
     
     
         3 . The method of  claim 1 , further comprising:
 determining a damage accumulation rate for the one or more pumps;   determining the damage accumulation rate exceeds a threshold; and   transmitting a warning.   
     
     
         4 . The method of  claim 1 , wherein the desired pumping rate corresponds to at least a fraction of a desired overall pumping rate for a group of pumps. 
     
     
         5 . The method of  claim 4 , wherein at least two pumps of the group of pumps operates at a different pumping rate. 
     
     
         6 . The method of  claim 4 , wherein at least two pumps of the group of pumps have different adjustments. 
     
     
         7 . The method of  claim 1 , wherein information is transmitted from the one or more pumps from respective sensors. 
     
     
         8 . A method for regulating one or more pumping rates of an electrically powered hydraulic fracturing pump system, comprising:
 receiving a desired pumping rate for a first pump;   determining a current pumping rate of an adjacent or opposite second pump;   determining a difference between the desired pumping rate and the current pumping rate is within a threshold amount;   applying an adjustment to the desired pumping rate.   
     
     
         9 . The method of  claim 8 , further comprising:
 determining the difference between the desired pumping rate and the current pumping rate exceeds a threshold amount; and   modifying at least one of the current pumping rate or the desired pumping rate.   
     
     
         10 . The method of  claim 8 , further comprising:
 determining a step rate for the first pump.   
     
     
         11 . The method of  claim 8 , wherein the step rate is based, at least in part, on a pump speed, crankshaft rpm, or critical plunger speed. 
     
     
         12 . The method of  claim 8 , wherein the desired pumping rate corresponds to at least a fraction of a desired overall pumping rate for a group of pumps. 
     
     
         13 . The method of  claim 8 , wherein information is transmitted from the one or more pumps from respective sensors. 
     
     
         14 . The method of  claim 8 , wherein the desired pumping rate is transmitted from at least one of an operator at a well site or a database communicatively coupled to a controller associated with the first pump. 
     
     
         15 . The method of  claim 8 , further comprising:
 determining a damage accumulation rate for the first pump; and   determining the damage accumulation rate is below a damage threshold.   
     
     
         16 . The method of  claim 8 , further comprising:
 determining a damage accumulation rate for the first pump;   determining the damage accumulation rate exceeds a damage threshold;   transmitting a warning.   
     
     
         17 . The method of  claim 16 , further comprising:
 receiving confirmation, from an operator, to apply the adjustment.   
     
     
         18 . A hydraulic fracturing system for fracturing a subterranean formation, comprising:
 a plurality of electric powered pumps, the plurality of electric powered pumps coupled to a well associated with the subterranean formation and powered by at least one electric motor, the plurality of electric powered pumps configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation;   one or more sensors receiving operating information from the plurality of electric powered pumps; and   a control system receiving the operating information and controlling at least one operating parameter of the plurality of electric powered pumps, wherein the control system is configured to apply respective step rates to adjust respective pumping rates for the plurality of electric powered pumps.   
     
     
         19 . The system of  claim 18 , wherein a first pump of the plurality of electric powered pumps is at least one of adjacent to or opposite a second pump of the plurality of electric powered pumps, and the first pump and the second pump operate at different pumping rates. 
     
     
         20 . The system of  claim 18 , wherein a total pumping rate for the plurality of electric powered pumps is controlled by the control system, the control system configured to individually adjust pumps of the plurality of electric powered pumps.